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Gen1 Cam Chain Tensioner (CCT) Replacement Lessons Learned


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#21 Ignacio

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Posted 13 June 2009 - 06:59 PM

Big props to FJRBluesman for the detailed CCT replacement including pictures. clapping.gif

It helped tremendously and I have an 8 and 10mm ratchet wrench (actually the whole set) added to my toolbox. Still slow-going with 5-10 degree strokes , but critical to getting the lower bolt in and out.

Initially, I removed the old tensioner and didn't notice a significant difference in how hard it was to wind the springs, but once the new one was in and buttoned back up the 92,000 mile FJR is quiet once again at idle. And it was long past due, but you know how these kinds of projects gnaw at you...but not quite enough to do things until you've got a hard summer of miles in order.

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#22 FJRBluesman

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Posted 13 June 2009 - 09:13 PM

Glad it helped Ig. I too bought an entire metric set of those little ratcheting wrenches. Like guys need an excuse for more tools. wink.gif

Now that you've done it, it's not too bad, actually fairly simple.

Ride safe.
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#23 Silverbear

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Posted 17 June 2009 - 08:06 PM

QUOTE (FJRBluesman @ Jun 13 2009, 10:13 PM) <{POST_SNAPBACK}>
Glad it helped Ig. I too bought an entire metric set of those little ratcheting wrenches. Like guys need an excuse for more tools. wink.gif

Now that you've done it, it's not too bad, actually fairly simple.

Ride safe.



I tried to use the ratcheting wrenches, but am not able to get the head of the wrench over the bolt, as the body of the CCT is too close to it. My regular (non-ratcheting) wrench fits, but can't turn it at all in the narrow gap. My bike is a 2003, with 43K miles on it. The ratcheting set I have is from Sears. But, it is a GearWrench, and not a Craftsman. The last time I was at Sears I visually compared the Craftsman set's head thickness with the one I got, and they seemed to be about the same. So far all my attempts to get that bolt out have failed. Does anyone have an idea or solution that worked on their 2003 model?

Please let me know.

Thank you!

Silverbear

#24 Brodie

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Posted 17 June 2009 - 09:29 PM

QUOTE (Silverbear @ Jun 17 2009, 09:06 PM) <{POST_SNAPBACK}>
I tried to use the ratcheting wrenches, but am not able to get the head of the wrench over the bolt, as the body of the CCT is too close to it. My regular (non-ratcheting) wrench fits, but can't turn it at all in the narrow gap.... so far all my attempts to get that bolt out have failed. Does anyone have an idea or solution that worked on their 2003 model?


Wrenches are cheap, get several brands of 10mm 12 point box wrenches. Cut them up. Grind on them. Heat and bend them. Modify them in whatever way that will work. It may take half an hour to get the bolts out but it can be done.

You just have to be smarter than steel. tongue.gif


Brodie

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#25 SkooterG

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Posted 17 June 2009 - 10:13 PM

QUOTE (Brodie @ Jun 17 2009, 10:29 PM) <{POST_SNAPBACK}>
Wrenches are cheap, get several brands of 10mm 12 point box wrenches. Cut them up. Grind on them. Heat and bend them. Modify them in whatever way that will work.


You're assuming we have the other cool tools needed to modify the wrench.

Most of us don't. sad.gif
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#26 Brodie

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Posted 17 June 2009 - 10:26 PM

QUOTE (SkooterG @ Jun 17 2009, 11:13 PM) <{POST_SNAPBACK}>
You're assuming we have the other cool tools needed to modify the wrench.
Most of us don't. sad.gif


Bench vise, piece of pipe, propane torch, hammer, hack saw.

High tech tools - I agree.
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#27 Silverbear

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Posted 18 June 2009 - 04:53 AM

QUOTE (Brodie @ Jun 17 2009, 10:29 PM) <{POST_SNAPBACK}>
QUOTE (Silverbear @ Jun 17 2009, 09:06 PM) <{POST_SNAPBACK}>
I tried to use the ratcheting wrenches, but am not able to get the head of the wrench over the bolt, as the body of the CCT is too close to it. My regular (non-ratcheting) wrench fits, but can't turn it at all in the narrow gap.... so far all my attempts to get that bolt out have failed. Does anyone have an idea or solution that worked on their 2003 model?


Wrenches are cheap, get several brands of 10mm 12 point box wrenches. Cut them up. Grind on them. Heat and bend them. Modify them in whatever way that will work. It may take half an hour to get the bolts out but it can be done.

You just have to be smarter than steel. tongue.gif


Brodie


Brodie,

I was thinking along the same lines, but was hoping for a quicker, off-the shelf solution I have not thought of before.


Thanks for your suggestion, it seems I am heading that way.

Silverbear

#28 FJRBluesman

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Posted 18 June 2009 - 05:39 AM

QUOTE (Silverbear @ Jun 17 2009, 09:06 PM) <{POST_SNAPBACK}>
QUOTE (FJRBluesman @ Jun 13 2009, 10:13 PM) <{POST_SNAPBACK}>
Glad it helped Ig. I too bought an entire metric set of those little ratcheting wrenches. Like guys need an excuse for more tools. wink.gif
Now that you've done it, it's not too bad, actually fairly simple.
Ride safe.
I tried to use the ratcheting wrenches, but am not able to get the head of the wrench over the bolt, as the body of the CCT is too close to it. My regular (non-ratcheting) wrench fits, but can't turn it at all in the narrow gap. My bike is a 2003, with 43K miles on it. The ratcheting set I have is from Sears. But, it is a GearWrench, and not a Craftsman. The last time I was at Sears I visually compared the Craftsman set's head thickness with the one I got, and they seemed to be about the same. So far all my attempts to get that bolt out have failed. Does anyone have an idea or solution that worked on their 2003 model?

Please let me know.

Thank you!

Silverbear
Silverbear - I saw the GearWrench set at Sears and I thought the box end ring was too thick so I didn't buy it. Make sure the ratcheting wrench you buy has a very thin end on the box end, meaning not a big thick ring which would interfere with the CCT as you experienced. I used that picture from the Sears website because that one did fit on mine no issues. I cracked it loose with my standard box end, then used the ratchet for a bit then the rest easily came out by hand. I also left the upper bolt in after I cracked it loose so I could more easily take out the lower without having pressure form the CCT pushing against the bolt. I modified my original post to state that.

BTW - The CCT is the same part number on 2003 - 2005, so you should be able to do this with the tools mentioned. I did it, Iggy did it. If we can do it, anyone can. wink.gif

Good luck.
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#29 Silverbear

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Posted 18 June 2009 - 06:33 PM

QUOTE (FJRBluesman @ Jun 18 2009, 06:39 AM) <{POST_SNAPBACK}>
QUOTE (Silverbear @ Jun 17 2009, 09:06 PM) <{POST_SNAPBACK}>
QUOTE (FJRBluesman @ Jun 13 2009, 10:13 PM) <{POST_SNAPBACK}>
Glad it helped Ig. I too bought an entire metric set of those little ratcheting wrenches. Like guys need an excuse for more tools. wink.gif
Now that you've done it, it's not too bad, actually fairly simple.
Ride safe.
I tried to use the ratcheting wrenches, but am not able to get the head of the wrench over the bolt, as the body of the CCT is too close to it. My regular (non-ratcheting) wrench fits, but can't turn it at all in the narrow gap. My bike is a 2003, with 43K miles on it. The ratcheting set I have is from Sears. But, it is a GearWrench, and not a Craftsman. The last time I was at Sears I visually compared the Craftsman set's head thickness with the one I got, and they seemed to be about the same. So far all my attempts to get that bolt out have failed. Does anyone have an idea or solution that worked on their 2003 model?

Please let me know.

Thank you!

Silverbear
Silverbear - I saw the GearWrench set at Sears and I thought the box end ring was too thick so I didn't buy it. Make sure the ratcheting wrench you buy has a very thin end on the box end, meaning not a big thick ring which would interfere with the CCT as you experienced. I used that picture from the Sears website because that one did fit on mine no issues. I cracked it loose with my standard box end, then used the ratchet for a bit then the rest easily came out by hand. I also left the upper bolt in after I cracked it loose so I could more easily take out the lower without having pressure form the CCT pushing against the bolt. I modified my original post to state that.

BTW - The CCT is the same part number on 2003 - 2005, so you should be able to do this with the tools mentioned. I did it, Iggy did it. If we can do it, anyone can. wink.gif

Good luck.



Thanks, FJRBluesman!

I am going back to Sears, and get the wrench with the part number in your post. I have the replacement part on hand, just need to take out the old one first.

Silverbear

#30 Brodie

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Posted 18 June 2009 - 06:43 PM

QUOTE (Silverbear @ Jun 18 2009, 07:33 PM) <{POST_SNAPBACK}>
I am going back to Sears, and get the wrench with the part number in your post. I have the replacement part on hand, just need to take out the old one first.
Silverbear



Silverbear

Just remember once you take the propane torch and hammer to the gear wrench the Craftsman Guaranty is no good any more.

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#31 FJRBluesman

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Posted 19 June 2009 - 06:04 AM

QUOTE (Silverbear @ Jun 18 2009, 07:33 PM) <{POST_SNAPBACK}>
I am going back to Sears, and get the wrench with the part number in your post. I have the replacement part on hand, just need to take out the old one first.
Silverbear
Bring the part with you, and if you can, bring the upper bolt or a similar one to make sure it fits.

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#32 Wicked Webby

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Posted 19 June 2009 - 06:55 AM

FJRBluesman,

Nice post. Great photos and details.

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#33 vabrzn

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Posted 19 June 2009 - 07:36 AM

Good post ! Thanks
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#34 Silverbear

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Posted 28 June 2009 - 04:32 PM

QUOTE (FJRBluesman @ Jun 19 2009, 07:04 AM) <{POST_SNAPBACK}>
QUOTE (Silverbear @ Jun 18 2009, 07:33 PM) <{POST_SNAPBACK}>
I am going back to Sears, and get the wrench with the part number in your post. I have the replacement part on hand, just need to take out the old one first.
Silverbear
Bring the part with you, and if you can, bring the upper bolt or a similar one to make sure it fits.


FJRBluesman

Well, I went back to Sears - twice. The first time I got the 8mm ratcheting wrench you mentioned in your post. You were right, it is much thinner than the GearWrench I got earlier. But, the gap between the CCT body and the bolt head was too tight, and when the wrench almost went on the bolt, the bottom of the wrench was resting against the bottom edge of the frame spar - no movement was possible. What ended up working like a charm for me though, is a long 1/4 in. wobble extension that I got as part of a kit from Harbor Freight, a 1.5 in long, 1/4 in. wobble extension from Sears, and an 8 mm socket. I pushed the socket (mounted onto the 1.5 in wobble extension) onto the long wobble after I passed that through the frame slot. In seconds I was able to loosen and unwind the lower bolt half way, then I just turned the bolt with my fingers (from top and bottom) until the bolt came out completely. Your instructions for removing the CCT through the bottom worked out great, and in no time I was able to reinstall the new CCT by reversing the steps. The double wobble contraption worked great for tightening the bolts also (top and bottom).

Thanks again for you post and all your suggestions!

Sincerely,

Silverbear

#35 Harvey

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Posted 07 August 2009 - 09:32 AM

My 2005 ticking seems to have gone away with a bottle of Techron.
I now realize that my cam chain is making noise.
The dealer says that it is "not excessive".

I ordered a new CCT and gasket. I already have the tools.

I ordered the parts and I think I can do it myself.

Thanks for all the work you have done on this great post!

This forum has been a great help to me and my FJR.

~Harvey

#36 charismaticmegafauna

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Posted 07 August 2009 - 09:36 AM

QUOTE (Harvey @ Aug 7 2009, 02:32 PM) <{POST_SNAPBACK}>
My 2005 ticking seems to have gone away with a bottle of Techron.

Wow..., that was easy...!!
unsure.gif ohmy.gif smile.gif
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#37 Harvey

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Posted 07 August 2009 - 12:12 PM

QUOTE (charismaticmegafauna @ Aug 7 2009, 09:36 AM) <{POST_SNAPBACK}>
QUOTE (Harvey @ Aug 7 2009, 02:32 PM) <{POST_SNAPBACK}>
My 2005 ticking seems to have gone away with a bottle of Techron.

Wow..., that was easy...!!
unsure.gif ohmy.gif smile.gif


Funny how when you get rid of one noise, you hear another that was there all the time.




#38 RadioHowie

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Posted 07 August 2009 - 12:12 PM

QUOTE (Harvey @ Aug 7 2009, 01:32 PM) <{POST_SNAPBACK}>
.....my cam chain is making noise.
The dealer says that it is "not excessive".


Yeah....he won't have to pay for it if your motor goes "BOOM!"


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#39 Harvey

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Posted 17 August 2009 - 03:12 PM

About that internal screw in the CCT:
Does it rotate as the plunger moves?
If not, how many times do I turn it CCW after the CCT is installed?
Thanks.

#40 johnny80s

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Posted 17 August 2009 - 03:22 PM

QUOTE (Harvey @ Aug 17 2009, 04:12 PM) <{POST_SNAPBACK}>
About that internal screw in the CCT:
Does it rotate as the plunger moves?
If not, how many times do I turn it CCW after the CCT is installed?
Thanks.


You just twist it and it will spring into position. You will feel it unwind.
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